Method and apparatus for forming articles by deposition



Aug. 24 1926. 1,596,976

' M. JAEGER METHOD AND APPARATUS FOR FORMING ARTICLES BY DEPOSITIONFiled Nov. 25, 1920 2 Sheets-Sheet 1 Swvmtoz Max Jagger Aug. 24 1926,.,5

M, JAEGER METHOD AND APPARATUS FOR FORMING ARTICLES BY DEPOSITION FiledNov. 23, 1920 2 Sheets-Sheet 2 I Mar Jagger M WM Patented Aug. 24,1926.

UNITED STATES PATENT OFFICE.

MAX JAEGER, OF LONG ISLAND CITY, YORK, ASSIGNOR TO ANCHOR CAP ANDCLOSURE CORPORATION, OF BROOKLYN, NEW YORK, A CORPORATION OF NEW YORK-METHOD AND APPARATUS FOR FORMING ARTICLES BY DEPOSITION.

Application filed November 23, 1920. Serial No. 425,967.

The present invention relates broadly to molding and more specially tothe formation of objects in molds by means of deposition.

The principal object of the present invention is a method and apparatusfor forming molded objects by deposition under fluid pressure frommaterial. supported in and carried by a suitable fluid and wherein themovement of fluids for accomplishing the molding is substantiallycontinuous in one direction.

A further object of the present invention is a method and apparatus formolding articles from material suspended in a suitable fluid bysegregating the material from the fluid by the walls of the mold andwherein the movement of the pressure applying fluid is substantiallycontinuous in one direction. a

A stillIfurther object of thepresent invention is a method and apparatusfor molding articles from paper pulp or the like suspended in water orsome other medium by flowing the pulp i'nto porous or foraminous moldsadapted to permit. the escape of the carrying fluid for the pulp fibers,and maintaining the fluid in the mold under pressure, which pressure iscontinued while the fluid and excess pulp is permitted to escape so thatthe fluid pressure continuing after the deposition of the pulp may beutilized for compacting and drying deposited pul A still further objectof the present in vention is a method and apparatus for molding articlesfrom liquid paper pulp or the like which comprises forcing the liquidpulp into the mold under pressure, by permitting the pulp carryingmedium to pass out through the mold wall and applyingba drying gas tothe deposited material y maintaining the gaseous pressure which is.

adapted to be admitted to the mold when the excess liquid pulp escapesfrom the mold.

A still further and more specific object of the present invention is-amethodand apparatus for molding articles from paper pulp or the likewhich comprises maintainingpaper pulp in a porous mold by means ofgaseous pressure until a suitable deposit of paper pulp fiber has 158611laid 011 the mold the present invention is a method and apparatus formolding articles from paper pulp or the like which comprises arranging asupply of liquid pulp, providing a suitable mold above said liquid pulpsupply, raising the liquid pulp into the mold by apply ing gas pressureto the surface of the liquid pulp, and continuing the supply of pulp tothe mold until a suitable amount of fiber has been deposited on the moldwalls, then opening the supply conduit to the mold at a point above thesurface of the liquid pulp supply and. permitting the excess liquid pulpto drain from the mold while gaseous pressure enters into the mold.

Other and further objects of the present invention will in part beobvious and will in partbe pointed out hereinafter by reference to theaccompanying drawings wherein like parts are represented by likecharacters throughout the several figures thereof.

Realizing the present invention may be embodied in constructions otherthan those specifically illustrated and described it is desired that thepresent disclosure shall be considered as illustrative and not in thelimiting sense.

Figure 1 is a'more or less diagrammatical view illustrating one form ofapparatus for carrying o-ut..the method embodying the present invention:

Figure 2 is a detail view illustrating the control valve closed withpulp being fed to the mold and with the pulp container illustrateddiagrammatically;

Figre 3 is a view similar to Figure 2 showing the control valvefullyopened-after the difliculty has been encountered in securing uniformdeposition over the side walls and at the same time constructionsrapidly rotating molds are not well adaptable for simple eiiicientmachines. Another form of mechanism for producing pulp articles hascomprised rotating mandrils supplied by pick up rollerswhich aredipped-into the pulp supply and deposit the same upon the said mandrils.This method and arrangement has been particularly adaptable formanufacturing fro-n11 fiber large articles such as buckets or wash tubsbut is relatively slow in operation and not well adapted for smallarticles. Neither is this method and apparatus desirable for rapidlyoperating automatic machines.

Another and common form of method and mechanism for use in this art'hascomprised mold forms adapted to dip into the pulp and be charged bysuction which draws the fibers against mold surfaces of the mold Thesesurfaces are usually arranged for pressing, either by pressing two moldsurfaces together or by applying a third forming surface to the materialgathered. The untility of this type of machine is limited to articlesformed of substantially solid pulp such as picnic plates, etc., and isnot adapted for the manufacture of hollow ,ware articles.

Another and general form of mechanism is that wherein a supply of pulpis provided and molds are charged from this pulp b-y suction. In mostcases the molds are arranged in the vacuum chamber and it is necessarythat this chamber be opened in order to open the molds. This method isadaptable for manufacture of small articles as well as large but isrelatively slow in operation because it is necessary to open the vacuumchamber each time the mold is open and usually a number of molds arelocated in a single vacuum so that the chamber cannot be opened withoutdisabling a number of molds. This means that it is necessary that theoperator be assured that all the molds within the chamber are correctlyfilled before the chamber ma be 'opened. In view of the fact that the 0ambers enclose the molds it is difficult to observe the action takingplace in individual molds and furthermore this typeof methodisrelatively slow because each time the vacuum chamber has opened adelay occurs before the next operation since it is necessary to exhaustthe chamber before the next ope-ration may be begun. There is still afurther difiiculty in connection with the use of this t of machine,especially where the method i employed in connection with automaticmachines in that it is diflicult to maintain vacuums of the requiredamount in automatically operated parts. There is still anotherdlfliculty which has been oncomprising countered in this t pe of deviceand that is that pressures wiich may be'applied to compacting thematerial against the mold 1s l1m1ted to atmosphere pressure which undersome conditions is not 'sufiiciently great to accomplish the workdesired.

The present invention comprisesa method and apparatus which willhereinafter be described in detail and which overcomes the difiicultiesof the known art by providing a method wherein the action of the moldmay be observed during the molding process, since the mold is stationaryand is not covered. Individualmolds may be operated without disturbingthe operation of other molds drawing from the same pulp supply and anypressure necessary or desirable may be applied without depending uponatmospheric pressure as the limit.

More specifically the present invention may broadly comprise a suitableforaminous mold operatively connected with a supply'of pulp whichpreferably is forced into the mold by gas ressure, for example,compressed air, and wherein the mold walls are uncovered so that theoperator may observe the flow of water, or ulp carrier, from the moldand thereby in go the deposit of the pulp in the mold. The depositingaction may bestopped at willby the opening of the pulp supplying conduitabove the surfaceof the pulpsupply so that the pulp will be returned tothe supply conduit at thesame time gas pressure over the pulp will.

enter the supply conduit as the pulp leaves the mold and will flow inthe same direction as the pulp was flowing so that the fibers on 'thewalls of the mold will be compactly laid in position. As the gas orcompressed air continues to escape through the fibers they are compactedagainst the walls of the mold. While the air escapes these fibers arebeing dried. The drying may be accentuated by using heated gas or air,as a pressure medium. In the present method the pressure maintained ispositive compressed gas pressure that operates on the interior of themold and therefore is not dependable upon exhaustion from around themold. This method and construction permits the adoption of a stationarymold for use in machines where large numbers of individual molds aresupplied from single sources of pulp-supply and wherein the severaloperating movements may be controlled by continuously driven automaticmachinery.

Referring to the drawings and more specially to Figure 1 wherein isillustrated one ably is separable, being held together by suitable-clampbolts 6 which compress the gasket member 7 The tank may carry .a spider8 which supports the funnel shaped pipe 9. The upper edges of the funnelshaped pipe are suitably machined or ground to form a valve seat for thevalve 10 which is carried upon the mold supply pipe 11. This mold supplypipe extends through a removable bushing 12 into which the mold supplypipe 11 is fitted with quick acting screw threads 14, Suitable packing15 is provided above the screw threads in order to prevent leakage ofair or other gas from the tank. In the embodiment'shown herewith themold supply tank is provided with an operating handle 16 by means ofwhich the pipe 11 may be turned, thereby causing the quick actingthreads 14 to quickly lift the valve 10 from its seat on the funnelshaped pipe 9. Preferably the upper end of the mold supply pipe 11carries a suitable sectional mold 17 beneath which maybe provided awater shed 18 which directs water escaping from the mold into the draintrough 19. This drain trough may be supported by brackets 20 or in anyother convenient or suitable way. An air ipe 21 leads to the supply tankand may e provided with an air valve 22 whereby air pressure may beadmitted to and cut off from said supply tank as is desired.

Assumingthe parts to be in the position illustrated in Figure 1 with thetank supplied with liquid pulp suflicient to immerse the lower portionof the funnel shaped pipe 9 and assuming that the air valve 22 is opento admit suitable air pressure above the pulp in the tank. The parts areshown in Figure 1 in position which they would occupy immediately afterthe valve 10 has been closed. Prior to the closing of the valve 10 thepulp in the container stands at the same height that the pulp in thefunnel shaped pipe 9 stands, in view of the fact that air pressure isequal on the pul in the pipe 9, and on the surface of t e liquid pulp 2.Immediately after the valve 10 is seated on the valve seatpressure onthe pulp in thetank forces the pulp u wardly in the funnel pipe 9because the mo (1 17 is porous or foraminous and consequently does notsupport internal air pressure, and consequently forms an outlet throughwhich the pulp seeks to escape. The pulp continues to arise andforms aseal around the lower end of the supply pi e. This tra s air under thevalve 10, as illustrated in i re 2. The pressure in the supply tank'contmues to force the pulp upwardly throu h the supply pipe 11 untilthe mold 17 is filled and continued pressure carries the (pulp fibersagainst the sidewalls of the mol In view of the fact that thematerial'of the mold is of such character as to catch and hold thefibers and at the same time is sufficiently orous or foraminous topermit the escape o the pulp carrying water, it will be obvious that thewater will flow through the'mold Wall while the fibers will be compactedagainst the interior of the mold. This action causes the fibers to buildup againstthe mold wall and the greater the deposit the greater theimpedance to the flow of water from that portion of the mold, and theless the fiow of liquid pulp toward the built up portion of the moldwall. In operation this factor establishes a very even deposit aroundthe mold wall for the following reasons. The pulp begins to depositagainst the lowermost portions of the mold where water escapes rstdue-to gravity action. This portion of the article builds up and forms awall having greater resistance to the escape of the water than the freerportions of the mold wall higher up. The result is that the carryingwater tends to escape through the path of least resistance until thatparticular path is built up in resistance, at which time the zoneescaping water moves to another point in the mold having lessresistance. This action continues until the entire surface of the moldwall is covered with deposited fibers of substantially thesamethickness. The resistance to the escaping water becomes substantiallyuniform over the entire mold surface at which time water will ooze outthrough the entire surface of the mold. This action will be observed bythe operator in view of the fact that the mold is uncovered, and whenthe operator is satisfied that sufiicient pulp has been deposited in themold to form proper walls for the desired article, the handle 16 isoperated to open the valve 10. As soon as this happens compressed airfrom the tank rushes in under the valve seat to equalize .the pressurein the funnel with that in the tank. This action, together with the factthat during operation air is trapped under the valve seat, keeps thevalve seat free from fiber. As soon as the valve leaves the seat the aireither carries the pul in .the supply pipe 11 into the mold an forcesthe carrying water out through the mold, or the excess pulp in the mold17 falls by gravity into the funnel pipe 9. The action of the pulp inthe supply pipe'll when the valve 10 is opened is largely dependent uponthe diameter of the supply pipe and the consistency of the pulp. If thediameter of the pi e 11 is smal or the pulp thickit will'be driven intothe mold .if the pipe 11 is large or the pulp thin it' will drain backinto the supply. As the pulp drops from the supply pipe 11, compressedair from the tank 7 rushes into the supply pi e and into the mold. The.movement of t is air it will be noted is in the directionthat the pulphas been traveling to fill the mold so that there excess pulp dropsaway. The

is a continuous direction of travel of pressure which tends to preventany loosening of the fibers from the mold wall when the nip quicklydrains from the supply pipe-and the air continues' to rush into the moldand escapes through mold walls in the direction of the water whichescaped from the mold. This action produces pressure on the interior ofthe deposited pulp which is far greater than the pressure on theexterior of the mold andv consequently compacts pulp fibers tightlyagainst the mold wall. Where desired hot gas or heated air may beutilized in the apparatus and thereby more quickly dry the fiberscompacted against the mold wall. When the operator is satisfied that thepulp in the mold is sufficiently dry to sustain the molded shape thesectional mold 17 may be opened and the article removed. While removingthe article from the mold the operator may find it desirable to cut ofithe supply of compressed air by means of the airvalve 22 which may bereopened immediately after the article is removed. 1

From the foregoing it will be clear that applicant has produced a simplemechanism capable. of rapid operation to produce molded articles andwherein the pressure by which the molding is accomplished is not limitedto atmospheric pressure.

Having thus described my invention what I claim is: 4 p

.1. The method of molding articles from liquid pulp which comprisesproviding a suitable supply of pulp, applying com pressed air to thesurface of said pulp, leading the pulp upwardly through a suitableconduit to a suitable foraminous mold, opening said conduit above thesurface of the supply of pulp when a desired deposit has been obtainedon the. walls of the mold and permitting compressed air from over thepulp supply to be forced into the mold and compact the depositedmaterial against the side wall ofthe mold.

2. An apparatus for molding articles from pulp or the like 'comprisin aclosed vessel, a conduit extending into said vessel and being adapted tohave a portion extending be low the surface of pulp in the vessel andanother portion above said surface, said conduit being provided with avalve seat in the portion adapted to be above the surface of pulp in thevessel a valve adapted to cooperate with said seat, a conduit controlledby said valve, a mold connected with said conduit, means to operate saidvalve, and means to supply compressed air to said closed ves- 3. Anapparatus for molding articles from paper pulp or the like comprising aclosed vessel adapted to contain a suitable supply of pulp, a pipewithin said vessel and adapted to extend into the pulp within the vessela valve arranged to open and close said pipe, a conduit leading fromsaid pipe, a mold operatively connected with said conduit,

means to supply compressed air to said vessel, and means to open andclose said valve to admit compressed air to the mold.

4. An apparatus for molding articles from pulp comprising a containerfor a supply of pulp, a conduit in said containerbeing provided on theupper end with a valve seat, a valve adapted to cooperate with saidValve seat and to trap air beneath said valve when pulp is raised insaid conduit, a pipe leading from said valve, a mold operativelyconnected with said pipe, and means to supply said container with fluidpressure.

5. An apparatus for molding articles from pulp comprising a closedcontainer, a funnel shaped member in said container being adapted toextend beneath the supply of pulp, a valve adapted to seat on the upperend of said funnel shaped member, a pipe leading through saidvvalve andinto said funnel shaped container in such manner as to provide a trapwhen said valve is seated,

a suitable mold connected with said pipe,

and means to lead a supply of compressed air'into said container.

6. In an-apparatus for molding articles from liquid pulp or the like,the combination of a container for liquid pulp, a vertically extendingpipe within said container,

a funnel shaped upper end on said pipe with the end thereof comprising avalve seat, a mold supply pipe extending into said funnel shaped portionof said conduit, a valve mounted upon said pipe and being adapted toseat on said funnel shaped member and to provide an air trap when saidvalve is closed, and means for opening and closing said valve.

ice

7. The method of maintaining a valve.

seat clear of material controlled by said valve, which method comprisesproviding a'zone of low pressure on one side of said valve and a zone ofhigh pressure on the other side of said valve seat, moving materialcontrolled by said valve through the valve and without crossing thevalve seat, whereby when said valve is opened pressure tends to equalizeacross said valve seat and to prevent said material from contacting withthe said valve seat.

8. In the pulp molding art, the method of maintaining valve seats freefrom pulp which method comprises passing the pulp through the valve andout of contact. with the valve seat, maintaining a zone of low gaspressure adjacent one side of the valve seat, and maintaining a zone ofhigh pressure adjacent the other side of the valve seat whereby whensaid valve is opened the equalization of pressure takes place across thevalve seat and tends to carry the fibers away from said valve seat.

9. In a pulp machine of the like for molding articles from paper pulp orthe like, a valve for controlling the flow of the pulp, said valvecomprising a valve seat formed on a cup shaped member, a valve adaptedto contact with said seat, a conduit controlled by said valve, saidparts being constructed to form a gas trap adjacent the seat for saidvalve in such manner that the pulp when passing through said conduit ismaintained out of contact with said valve seat 10. As an article ofmanufacture, a valve comprising a cup shaped member provided on one end'witha valve seat, a cooperating member being adapted to engage saidvalve seat and close said cup-shaped member, a conduit extending throughsaid cooperating member and into said cup shaped member in such manneras to form a gas trap when liquids are forced through said cup shapedmember and said conduit in valve seat, a conduit extending from saidcooperating member in such manner as to form a trap with the valve seatwithinthe trap so that the material flowing through said member ismaintained out of contact with the valve seat.

12. In a system for conveying liquid pulp or the like a valve forcontrolling the flow of the material conveyed, said valve having a seat,and said seat being protected from the material conveyed by a zone oftrapped fluid.

MAX JAEGER.

